An epic steak sandwich is one of the best ways to enjoy steak. Below is a clear, flavorful version of my favorite Traeger Grilled Steak Sandwich—made on a pellet grill with caramelized onions, a bright horseradish aioli, and smoked cheddar for a truly next-level bite.
Traeger Grilled Steak Sandwich
There’s an old saying: if you’re going to go, go all out. That’s exactly how this sandwich started. I pulled a couple of ribeyes from the fridge, rubbed them generously, and fired up the pellet grill. A cast-iron pan went on the grill for slowly caramelizing thinly sliced onions while the steaks seared hot and fast. I mixed real horseradish with a rich mayo and a touch of garlic for a punchy aioli, then layered everything on a freshly baked French loaf with slices of smoked cheddar. The result was rich, savory, and perfectly balanced.
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Recipe Shopping List
Everything you need to make this sandwich is straightforward. For exact quantities, refer to the ingredients list in the recipe section below.
- Ribeye steaks (or your preferred steak)
- Beef rub or simple salt and pepper
- Olive oil
- Yellow or sweet onion
- Mayonnaise (Kewpie or Duke’s recommended)
- Horseradish
- Garlic paste or powder
- Smoked cheddar
- Freshly baked French bread loaf
75+ favorite Traeger recipes available from the same collection.
How To Make This Recipe
Here’s an overview of the method so you know what to expect. Scroll to the full recipe for precise ingredient amounts and timing.
- Preheat – Heat your Traeger or pellet grill to 400–425°F. Place a cast-iron pan on the grill as it heats so the pan gets hot for the onions.
- Season – Generously season the steaks with beef rub or a simple salt-and-pepper blend.
- Caramelize Onions – Add a tablespoon of olive oil to the hot cast-iron pan and add thinly sliced onions. Close the lid and let them cook, stirring often. Aim for deep golden brown, not burned.
- Sear the Steaks – Once onions are done, remove the pan. Place steaks directly on the grill and cook 8–10 minutes before flipping. Continue until the internal temperature reaches 125–130°F for medium-rare; adjust to your preferred doneness. Let the steaks rest after removing.
- Toast the Bread & Make Aioli – Halve the French loaf and place cut-side-down on the grill until lightly toasted. Mix mayonnaise, horseradish, and garlic paste for the aioli.
- Assemble – Spread aioli on both cut sides of the toasted bread, slice the steak against the grain, and arrange on the bottom half. Top with caramelized onions and smoked cheddar. If you prefer the cheese melted, wrap the sandwich in foil and return to the grill for a few minutes.
- Serve – Slice into portions and serve hot. This sandwich pairs well with a crisp pickle or simple green salad.
Try grilled seafood or other large cuts for alternate cookouts.
Recipe FAQ
Yes. Choose a steak you enjoy on its own: New York strip, flat iron, or even a filet will work. For a more budget-friendly option that slices thin, try skirt or flank steak. Adding bacon is an optional upgrade.
Mostly, yes. For the best texture, cook the steak just before serving and toast the bread right before assembly. If you need to transport the sandwich, keep the aioli separate and assemble at your destination to avoid soggy bread. A cold steak sandwich can still be excellent, especially with the crunch of toasted bread.
Also great: Prime rib pinwheel-style sandwiches and other hearty steak builds.
More Steak Recipes
- Smoked Butter-Basted Prime Rib
- Traeger Ribeye
- Grilled T-Bone
- Grilled Tomahawk
- Sirloin Cap Steak
Also consider a fork-tender smoked pot roast for a different, comfort-food style meal.
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Traeger Grilled Steak Sandwich
This grilled steak sandwich is seared hot on a pellet grill and finished with caramelized onions, a horseradish aioli, and smoked cheddar for a rich, smoky flavor.
5 minutes
15 minutes
20 minutes
Ingredients
Sandwiches
- 2 ribeye steaks
- 1 tablespoon beef rub (or salt & pepper)
- 1 tablespoon olive oil
- 1 large sweet onion, thinly sliced
- 1 loaf freshly baked French bread
- 6 ounces smoked cheddar cheese, sliced
Horseradish Aioli
- 2 teaspoons prepared horseradish
- ½ cup mayonnaise (Kewpie or Duke’s recommended)
- ½ teaspoon garlic powder
Instructions
- Preheat your Traeger or pellet grill to 400–450°F. Place a cast-iron pan on the grill to preheat.
- While the grill heats, season both steaks evenly with the beef rub or salt and pepper.
- Heat olive oil in the cast-iron pan and add the sliced onions. Close the grill and cook, stirring frequently, until the onions are deep golden brown.
- Remove the pan when onions are done. Place the steaks on the grill and cook until the internal temperature reaches 125–130°F for medium-rare, flipping once. At the same time, place the halved bread cut-side-down on the grill to toast.
- Remove steaks and let rest for several minutes before slicing.
- Combine horseradish, mayonnaise, and garlic powder to make the aioli. Spread aioli on both sides of the toasted bread.
- Slice steak thinly across the grain, pile onto the bottom half of the bread, top with caramelized onions and smoked cheddar, then finish with the top half of the loaf. Wrap in foil and return to the grill for a few minutes if you want the cheese melted.
- Slice into servings and enjoy while hot.
Nutrition Information:
Yield: 4
Amount Per Serving:
Calories: 852
Total Fat: 49g
Saturated Fat: 16g
Cholesterol: 87mg
Sodium: 1202mg
Carbohydrates: 69g
Fiber: 3g
Sugar: 10g
Protein: 34g
Nutrition data provided here is an estimate.